Method and means of producing multiform containers from pre-cut blanks in a container-forming machine



Feb. 1s, 1969 D. WAINBEG 3,427,931

METHOD AND MEANS OF PRODUCING M ULTIFORM CONTAINERS FROM PRE-CUT BLANKSINA CONTAINER-FORMING MACHINE Filed April 1.9, 1966 Sheet of 2 FIG. l.

INVENTOBR. DANIEL WAINBERG Feb. 18. 1969 D. WAINBERG 3,427,931 METHODAND MEANS OF PRODUCING MULTIFORM CONTAINERS FROM PRE-CUT FORMING MACHINEBLANKS IN A CONTAINER* Sheet Filed April 19. 1966 Cul United StatesPatent O METHOD AND MEANS OF PRODUCING MULTI- FORM CONTAINERS FROMPRE-CUT BLANKS IN A CONTAINER-FORMING MACHINE Daniel Wainberg, 4755Blvd. des Grandes Prairies,

St. Leonard, Montreal 38, Quebec, Canada Filed Apr. 19, 1966, Ser. No.545,211

U.S. Cl. 93--51 1 Claim Int. Cl. B31b 1/44, 11/00, l/26 ABSTRACT OF THEDISCLOSURE A method of producing a multiformity of containers frompre-cut blanks of various sizes and shapes in a container formingmachine without interrupting the continuous operation of the containerforming machine, and which consists in having a paradigm of a specifiedtype of container blank which conforms with the dimensions of theplunger head and forming die and the blank handling structures of themagazine and feeding mechanism, the paradigm comprising a bottom wall ofa predetermined length and `width and provided with integralend wallsand side walls, the widths of the end walls and the lengths of the sidewalls being identical with the width and length of the bottom wall. Theside walls are provided with integral locking flaps, and locking meansare formed inthe end walls and the locking flaps and are an integralpart thereof, the length and width of the locking flaps beingcomparatively the same length and -width as the portions of the endwalls that encompass their locking means. The multiformity of thepre-cut blanks may differ with respect to their configurations and sizesfrom the paradigm from which they are patterned, always providing thatsuch blanks maintain approximately the same lengths with respect totheir bottom walls and accompanying side walls as to the correspondingparts of the paradigm, as well as maintaining the same width of theirbottom walls and their integral end walls, together with the lengths andwidths of their locking flaps maintaining the same lengths and widths asthe portions of the end walls that encompass their locking means, all inaccordancewith the corresponding sizes in the said paradigm, andtheblank handling structures of the magazine and the feeding mechanism andthe dimensions of the plunger head and the forming die lendingthemselves to the differences of configurations and sizes of themultiformity of pre-cut blanks with respect to the paradigm in theformation of such blanks into containers.

The invention relates to a method and means of producing multiformcontainers from predetermined precut blanks in a container-formingmachine, as described in the present specification and illustrated inthe accompanying drawings that form a part of the same.

The invention consists essentially in the novel method and means ofproducing a multiformity of containers from predetermined pre-cutblanks, Iwithout disturbing the continuity of operation in a containerforming machine, as pointed out broadly and specifically in the claimsfor novelty following a `description containing an eX- planation indetail of an acceptable method and means of carrying out the invention.

In the past and up to the present time, the method of setting upcontainers from pre-cut foldable sheet material is generallyaccomplished by the -use of mechanical means for their erection, such asautomatic folding machines of the conveyor type, folding machinesincorporating the plunger head and forming die type of mechanism, andother types. Many of these container forming machines are very efHcientfor their purpose, but are restricted in their use to single continuanceruns of forming containers from pre-cut blanks to only one particularsort of container at a time, as otherwise, whenever a |different size,shape or style of container is required to .be erected, it is necessaryto stop the operation of the machine and change the handling, carryingand folding mechanisms thereof, in accordance with the new type or sizeof the pre-cut yblank to be erected into a container.

In many instances, the automatic container forming machines areconstructed to include multiple sets of handling, carrying and foldingmechanisms so as to permit similar or different types of pre-cut blanksto be formed into containers through concurrent or separate operatingruns, which is a costly procedure and requiring the unnecessaryduplication of equipment to accomplish the purpose, but again thissystem does not avoid the need of changing the handling, carrying andfolding mechanisms of the individual sets in forming containers of othersizes or shapes, and in the majority of cases, the operation of themachine has to cease until such changes and adjustments have been made.

In container forming machines of the plunger and forming die type, whichis now practically universal, it is necessary to stop the operation ofthe machine in order to make adjustments and change-overs to the varioushandling, carrying and folding means, whenever it is required to erectother styles, shapes or sizes of containers. This causes undue relaysand reduction to the output of production, as well as loss of time andlabour, increases costs and adds to the possibility of human errorsoccurring where manual or mechanical adjustments are required.

It is the purpose of this invention to avoid the necessity of changingthe handling, carrying and folding mechanisms in a container formingmachine every time a new style, shape and size of container is to beerected in the machine, and avoid the incessant times the machine has tobe stopped lfor such adjust-ments and changes, and other drawbacks inthe use of the present machines. lt is the further purpose of thisinvention to devise a method and means of producing a multiformity ofcontainers from predetermined pre-cut blanks for their erection `by asingle plunger head and forming die mechanism, and with the need oflittle or no adjustment or changes to the magazine, supporting thepre-cut blanks, feeding mechanism and other operational parts of themachine, and `without any interruption to the continuance of theoperation of the container forming machine.

An object of the invention is to devise :a method and means whereby thesame plunger head and forming die mechanism, installed in a containerforming machine, may be utilized for the erection of multiformcontainers and which will require little or no adjustment.

Another object of the invention is to minimize the necessity of havingspeciiied plunger heads and forming dies made for every size, style orshape of container to be formed, where a single plunger head and formingdie combination is capable of replacing them in the erection of amultiformity of containers.

A further object of the invention is to create a method and meanswhereby the arrangements and structures of the magazine, the feedingmechanism and the container forming mechanism of a container formingmachine, are so arranged and constructed that a multiformity ofpredetermined pre-cut blanks, made to conform with such arrangements andstructures, may be formed into containers during the same run withoutany interruption to the operation of the machine, or in the formation ofcontainers, in successive runs of one size, style or shape,

or runs of mixed sizes, styles or shapes of pre-cut blanks to be erectedinto containers.

A still further object of the invention is to minimize the need ofconstant substitution of plunger heads and forming dies for otherplunger heads and dies of different sizes, shapes and styles to conformwith predetermined types of pre-cut blanks for their erection intoformed containers, and thereinplace simply provide one kind of plungerhead and one type of forming die to do the work of the multiple types ofplunger heads and dies that would otherwise have to be used.

A still further object of the invention is to devise a method and meansof producing complete coordination between the magazine holding thepre-cut blanks, the feeding mechanism and the container formingmechanism to form containers of various sizes, shapes and styles, fromthe predetermined pre-cut blanks, without interfering with the constantoperation of the machine.

Still another object of the invention is to reduce the loss of time andlabour costs, the slowing down in the production of set-up containers,and in consequence, causing delays in the packaging of the comestiblesand other items into the formed containers, and thereby decreasing theoutput of the product, all being created through stoppages in theoperation of the container forming machine and the endless adjustmentsthat are ordinarily required through replacements, changes andalterations to the magazine for the pre-cut blanks, the feedingmechanism and the plunger head and forming die mechanism of the machine,by providing a method and means of producing a multiformity ofcontainers without having to change and adjust the various operationalparts of the container forming machine and thereby adding to itsversatility in the formation of various sizes and shapes of containerswithout having to stop the running operation of the machine.

Still another object of the invention is to create a method and meansfor the pre-cut blanks and the container forming machine that will speedup the production of erected containers and increase the quantity ofcompleted containers formed of varying sizes, styles and shapes and insmall or large quantities of the required amount of the individual typesof containers being formed in the machine through one type of plungerhead and die mechanism and in a continuous running operation.

A further object of the invention is to devise a method and means forforming multiform containers in a container forming machine that Willrequire little attention from the operator during its operativemaintenance, that will be simple to operate and maintain, and efficientfor its purpose.

A still further object of the invention is to arrange a method and meanswhereby a limited leeway will be allowed to permit an increase in thelength and/or the width of certain types of pre-cut blanks tht are madefrom a model paradigm without interfering with the lengths and widths ofthe other types of pre-cut blanks that are made from the same patternand being formed through the same run of operation or any runs thereof`of the container forming machine as are the other pre-cut blanks.

Other objects and novel features of the invention will appear more fullyhereinafter from the consideration of the folowing detailed descriptionwhen taken in connection with the accompanying drawings illustrative ofan acceptable method and means of carrying out the invention. It isexpressly understood, however, that the drawings are utilized forpurposes of illustration only and are not to be taken as a definition ofthe limits of the invention, reference being had for this latter purposeto the appended claim.

In the drawings:

FIGURE l is a diagrammatic view illustrating a method and means forerecting a multiformity of containers in a single running operation of acontainer forming machine.

FIGURE 2 is a plan view of a model paradigm of a pre-cut blank for acontainer and from which a conformity of pre-cut blanks for various sizecontainers may be based for mass production.

FIGURE 3 is a plan view of a plurality of multiformity of predeterminedpre-cut blanks that are superimposed over one another and illustratingthe portions of the pre-cut blanks that are in uniformity with oneanother and the other portions thereof that are not in uniformity withone another.

FIGURE 4 is an enlarged fragmentary view of a magazine supporting amultiformity of pre-cut blanks placed in an endwise position thereon andready to be individually removed therefrom.

Like numerals of reference indicate corresponding parts in the variousrfigures.

The materials used for making blanks for the containers are diversified,such as cardboard, pasteboard, other pulp material, plastic, aluminum,composite materials and any other type of material that will lend itselfto be made into a pre-cut blank, capable of being folded to form therequisite container, may be utilized.

These one-piece blanks may be cut into diversified shapes, styles andsizes to form the predetermined type of c-ontainer required and providedwith the necessary crease lines, integral locking means, glue flaps andany other means for joining and securing the upright walls of acontainer to one another, so long as they are based on a model paradigm,which in turn will conform with the paradigm of the plunger head andforming die mechanism, and the handling and carrying mechanisms of thecontainer forming machine.

An example or pattern of one type of pre-cut blank, as shown in FIGURE2, may form a basis from which a multiforrnity of pre-cut blanks fordifferent sizes and shapes of containers are made. In this instance, thepattern has the bottom wall, as indicated by the numeral 15, made of apredetermined width and length, and the dimensions of which will remainconstant in all of the conformity of containers that are producedtherefrom. The end walls 16 and 17 are integral with the bottom wall 15and separated therefrom by the crease or folding lines 18 and 19, thewidth of the end walls being identical with one another and identicalwith the width of the bottom wall. These widths will always remain thesame regardless of any variations in the size, shape and style of thecontainer that will be constructed from the basis of the pattern.

The side walls 20 and 21 are integral with the bottom wall 15 and areseparated therefrom by the crease or fold lines 22 and 23 and whichterminate at the ends of the crease lines 18 and 19. In all instances,the length of the side walls will coincide with the length of thebottom. The side walls are `provided at their ends with the integrallocking or extension iiaps 24, 25, 26 and 27 that are separated from theside walls by the crease or fold lines 28, 29, 30 and 31 and are inalignment with the crease lines 18 and 19. The locking or extension apshave the locking members 32, 33, 34 and 35 integral therewith and whichare adapted to engage with the slits 36, 37, 38 and 39 that are formedin the end walls 16 and 17, the description and operation of which beingsimilar to the disclosure set forth in the United States patent toDaniel Wainberg and issued on June 29, 1965, under Number 3,191,845.

The length of the locking or extension flaps remains approximately thesame throughout the various multiformity of containers or cartons thatare made from the above-mentioned model paradigm, so long as the lengthincludes the locking members and also up to their minimum height, sothat in the lateral position of the locking flaps, the locking membersmay be inserted through the slits of the end walls.

The depth of the multiformity of the containers may be of any height solong as the length and width of the containers remain approximately thesame and may be provided with or without dust flaps, covers and closureaps.

The model paradigm, as shown in FIGURE 2, con sists of a pre-cut blankrepresenting a tray style of container and which may be used as apattern for making a multiformity of pre-cut blanks, since the basis ofthe pattern, as already described, will be followed in regard to theapproximate length and width of the container, but from there on themultiformity of the containers may be altered, such as the differencesin depth of the container, the style of the container, such as adding anintegral cover, dust flaps, closure flaps, the use of picture windowsand other ornamental features, as well as the shape or contour of thecontainer.

In FIGURE 3 a plurality of pre-cut blanks of varying sizes are shown assuperimposed one over the other and constructed to follow the basis ofthe model paradigm, which in this instance, is in the form of a tray 15,but from thereon, the different pre-cut blanks 40 vary in depth from oneanother by varying the height of their upright side walls 41 and endWalls 42, as well as the attending extension or locking flaps 43.

When it is required to have a specified quantity of several multiformityof pre-cut blanks to be run into and through the container formingmachine for their erection into completed containers, during acontinuous operational run of the machine, the pre-cut blanks ofdesignated sizes, shapes and styles are placed endwise -on the conveyorsupporting arms 44 of the magazine 45 that is secured to the containerforming machine, and are adapted to be individually removed from themagazine through the gate 46 by the pick-up members 47 of the feedingmechanism 48.

The supporting arms 44 are adjusted in respect to their lateral positionwith one another so that they will engage with the lower edges of theend walls of the pre-cut blanks that have the shortest length, which inthis instance will be the length of the end walls of the model paradigm,and in this way assure the proper support of the multiformity of pre-cutblanks that have been made in accordance with the pattern and thedimension of the forming die.

The feeding mechanism, through its pick-up mechanism, will remove thepre-cut blanks, one at a time, from the magazine and placed over anda-cross the top face of the throat 49 of the forming die 50, the plungermechanism 51 is then brought into operation for pushing the blankthrough the throat of the forming die and expelling the thus formedcontainer fromthe forming die onto the conveyor 52 for its removal tothe packers or persons for filling and for other purposes.

The throat 49 of the forming die comprises parallel inner longitudinalfaces 53 projecting downwardly from the top edge surface 54 of thethroat and suitably shaped to provide the required folding means, andalso has the inner end faces 55 projecting downwardly from the top edgesurface or face 54, which completes the contour of the throat. Thediameter of the throat may be slightly larger than the basic pattern Iofthe model paradigm of the pre-cut blank, so as to allow leeway to permitlimited extension of the dimension of the length and/or width of certaintypes of pre-cut blanks that have been patterned from the modelparadigm, and Without interfering with other sizes of pre-cut blanksthat are being formed by the machine.

The plunger head 56 of the 4plunger mechanism, is placed in verticalalignment with the throat of the forming die and is adapted to be pushedtherethrough, so as to force the blank through the throat of the formingdie for its formation into `a container. The dimensions of the Yplungerhead are 'smalle-r than the dimensions of the throat of the forming dieand the difference in the space between the vertical faces of the throatand the vertical walls of the plunger head will lbe guided in accordancewith the dimensions of the model paradigm and including the leewaypermitting limited extension ofthe length and/ or the width of thepre-cut blanks that are based on the pattern of the model paradigm.

Although the invention has been described as being applied to theforming of a multiformity of pre-cut blanks into containers, and whichincludes containers having integral covers and closure flaps, it must beunderstood that the same means and methods could be applied for theformation of a two-piece container, such as a receptacle and adetacha-ble cover or lid, all made from the same model paradigm, thepre-cut blanks of which may be run through the container forming machinefor their erection into containers and lids therefor, all beingaccomplished during the same running operation of the machine withoutthe necessity of stopping the same for adjustments or changes in theoperational parts.

As various possible embodiments might be made of the above invention,and as various changes might be Amade in the embodiment set forth, it isunderstood that all matter herein set forth or shown in the accompanyingdrawings is to be interpreted as illustrative and not in a limitingsense.

What I claim is:

1. A method of forming containers from pre-cut blanks of varying sizesand shapes in a container forming machine without interrupting thecontinuous operation of the container forming machine, a feedingmechanism, a plunger head and a forming die capable of forming theblanks into containers, and characterized by the fact that a paradigm ofa specified type of container blank, which conforms with the dimensionsof the plunger head and the forming die and the blank handlingstructures of the magazine and feeding mechanism, is used as a patternfrom which a multiformity of container blanks are made, said pa-radigmcomprising a bottom wall of a predetermined length and width, end wallsintegral with said bottom wall and having their widths identical withthe width of said -bottom wall, side walls integral with the length ofsaid bottom wall, locking flaps integral with said sidewalls, lockingmeans for-med in said end walls and said locking flaps and being anintegral part thereof, the length and width of the locking flaps beingcompara tively of the same length and width as the portions of the endwalls that encompass their locking means; the multiformity of thepre-cut blanks may differ with respect to their configurations and sizesfrom the paradigm from which they are patterned, always provided. thateach of such blanks maintains approximately the same lengths withrespect to its bottom wall and its accompanying integral side walls asto the corresponding parts of `the paradigm, as well as maintaining thesame width of its bottom wall and its integral end walls, together withthe lengths and widths of its locking aps maintaining the same lengthsand widths as the portions of the end walls encompassing their lockingmeans, all in accordance with the corresponding parts in said paradigm,and the blank handling structures of the magazine and the feedingmechanism and the dimensions of the plunger head and the forming dielending themselves to the differences of configuration and sizes of themultiformity of pre-cut blanks with respect to the paradigm in theformation of such blanks into containers; and, the paradigm is made toform a pre-cut blank that is adapted to be erected into a tray, and theformation of a pre-cut blank patterned from said paradigm with respectto its length, width, locking flaps and locking means and diverging fromthe paradigm in that at least one side wall is extended in height toform an integral closure when the blank is: erected into a container bythe sa-me blank handling 4structures of the magazine and feedingmechanism and the plunger head and forming die of the container formingmachine that 7 comparatively conforms with the dimensions and shapeFOREIGN PATENTS 418,728 10/193'4 Great Britain.

of the said paradigm.

R f r n e Cited 890,504 2/1962 Great Britain. e e e c s 932,358 7/1963Greatritain. UNITED STATES PATENTS 2,270,185 1/1942 Dulmage 9? 51 XWAYNE A. MORSE, IR., Pfl'mlly Examiner. 2,832,270 4/1958 Pierce 93-51Us' C1. XR

3,065,679 11/1962 Clement 93-51 9336.01, 47, 49

